Garment-like disposable absorbent article having a bloused outer cover

ABSTRACT

A disposable absorbent article for wearing about a wearer&#39;s lower torso is provided. The disposable absorbent article comprises: a chassis; an absorbent assembly joined to the chassis; and seams joining the front portion of the chassis to the rear portion of the chassis so as to form two leg openings and a waist opening. A bloused outer layer has a pattern imprinted thereon such that the inner layer with the absorbent assembly joined thereto is substantially unnoticeable to a viewer thereby providing a very garment like appearance to the absorbent article.

This is a division of application Ser. No. 08/176,055, filed on Jan. 3,1994, allowed.

FIELD OF THE INVENTION

The present invention relates to disposable absorbent articles such asbaby diapers, children's training pants, adult incontinence garments,and the like. The present invention relates more particularly todisposable absorbent articles having fixed sides, such as disposabletraining pants, which are placed in position on the wearer by insertingthe wearer's legs into the leg openings and sliding the disposableabsorbent article into position about the wearer's lower torso.

BACKGROUND OF THE INVENTION

Infants, children, and other incontinent individuals wear disposableabsorbent articles to receive and contain urine and other bodilyexudates. It has become increasingly important for disposable absorbentarticles to be more garment-like in appearance. Absorbent articleshaving fixed sides, such as disposable training pants for use on toilettraining children, have become popular for use on toilet-trainingchildren. It is particularly desirable that disposable training pants bevery garment-like in appearance and feel so a toilet training child willdistinguish it from a diaper, will want not to soil them, and will moreeasily adjust to cloth undergarments.

Absorbent articles, generally comprise a liquid impervious thermoplasticbacksheet, a liquid pervious topsheet, an absorbent structure forabsorbing bodily exudates, and elastic legbands and waistbands to gatherthe article for fit and containment. The absorbent structure, elasticlegbands, and elastic waistbands are generally positioned between thetopsheet and the backsheet, and usually adhesively secured thereto. Thisgeneral structure is substantially liquid impervious, but is plastic infeel and resembles an absorbent article as a result of the absorbentcore or outline of the absorbent core being visible through thebacksheet.

Several structures have been developed to eliminate, as much aspossible, the feel of plastic and appearance of an absorbent article.One such structure utilizes a backsheet comprising a film-coatednonwoven. This backsheet comprises a thermoplastic film that is extrudedonto a nonwoven web. The heat of the film and the pressure appliedduring the process provides the adhesion between the film and nonwovenlayer. While the film does help to maintain the integrity of thenonwoven layer, it also results in a stiffer and less desirablebacksheet.

Another structure utilizes a backsheet comprising a thermoplastic filmlaminated to a nonwoven layer. The laminating is provided by applying anadhesive to the film or the nonwoven layer, and then attaching it to theother layers of the article. Thus, in both this second design and thefirst one mentioned above, the thermoplastic film and the nonwoven layerare joined totally along their mutually facing surfaces and theabsorbent core or outline thereof is still visible through thebacksheet.

Another structure utilizes a backsheet comprising an outer layer andinner layer which are intermittently or partially joined together. Sucha structure is more garment-like in appearance and feel. However, theabsorbent core is generally secured to the inner layer and is generallystill visible through the outer layer 18 of the chassis. This isparticularly true if there is a pattern or design printed on the innerlayer.

It is, therefore, an object of the present invention to provide anabsorbent article having a backsheet comprising an inner layerintermittently or partially joined to an outer layer which provides agarment-like appearance and feel and which substantially masks or hidesthe absorbent core or outline of the absorbent core from the viewer.

SUMMARY OF THE INVENTION

A disposable absorbent article for wearing about a wearer's lower torsois provided. The disposable absorbent article comprises: a chassis; anabsorbent assembly joined to the chassis; and seams joining the frontportion of the chassis to the rear portion of the chassis so as to formtwo leg openings and a waist opening. The chassis comprises. The blousedouter layer has a pattern imprinted thereon such that the inner layerwith the absorbent assembly joined thereto is substantially unnoticeableto a viewer thereby providing a very garment like appearance to theabsorbent article.

BRIEF DESCRIPTION OF THE DRAWING

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a perspective view of the disposable training pant embodimentof the present invention in a typical in-use configuration as it wouldbe applied to a wearer;

FIG. 2 is a top plan view of the chassis of the training pant embodimentof the present invention having portions cut away to reveal theunderlying structure, the surface which will form the outer surface ofthe disposable absorbent article facing away from the viewer;

FIG. 3 is a cross-sectional view of the chassis shown in FIG. 2 takenalong section line 3--3 of FIG. 2.

FIG. 4 is a cross-sectional view of an alternate embodiment of thepresent invention, wherein the absorbent assembly is an insert joined tothe inner layer of the chassis.

FIG. 5 is a cross-sectional view of another alternate embodiment of thepresent invention, wherein the earflaps of the absorbent article areelasticized.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, it will be noted that FIG. 1 is a perspectiveview of a disposable absorbent article in its typical in-useconfiguration. A disposable absorbent article is one which is intendedto be discarded after it is used (i.e., it is not intended to belaundered or otherwise restored or reused). The disposable absorbentarticle is provided with an absorbent assembly which is placed in closeproximity to the body of the wearer to absorb and contain the variousexudates discharged from the body.

A preferred embodiment of the disposable absorbent article of thepresent invention, disposable training pants 20, is shown in FIG. 1. Thetraining pants 20 of FIG. 1, basically comprise a chassis 14 comprisingan inner layer 16 and an outer layer 18; an absorbent assembly 22comprising at least an absorbent core 28, joined to the inner layer 16of the chassis 14; and a pair of side seams 10. Referring to FIG. 2, thechassis 14 comprises an inner layer 16 and an outer layer 18 which isjoined to the inner layer 16 such that the outer layer 18 will bebloused. The outer layer 18 has a pattern or insignia 15 printedthereon. The printed pattern or insignia 15 of the outer cover 18 tendsto draw the viewer's attention away from the underlying inner cover 16and thereby masks or hides the absorbent core (or the outline of theabsorbent core) which is bonded directly or indirectly to the innerlayer 16.

As used herein, the term "bloused" shall be understood to mean thatportions of a first-layer of material are unattached and loosely fittedto a second layer of material, i.e., portions of the first layer ofmaterial hang or have been caused to hang loose and full from the secondlayer of material to which the first layer is joined. As used herein,the term "joined" encompasses configurations whereby an element isdirectly secured to another element by affixing the element directly tothe other element, and configurations whereby the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element.

In a particularly preferred embodiment, the chassis 14 also compriseselastic waistband members 76, and elastic strands 105 secured to atleast the inner layer 16. FIG. 2 is a partially cut-away perspectiveview of the disposable absorbent article 20 of FIG. 1, prior to thefront portion 56 and rear portion 58 of the chassis 14 being securedtogether by the side seams 10. FIG. 2 shows the chassis 14 in itsflat-out, uncontracted state, i.e., with all elastic contraction pulledout of the elastic waistband members 76 and the elastic strands 105 ofthe elastic legbands 34. The chassis 14 of the present inventionpreferably has a modified hour-glass shape and is symmetric about thelongitudinal centerline l. The chassis 14 will have at least a frontportion 56, a rear portion 58, and a crotch portion 57.

CHASSIS

The inner layer 16 of the chassis 14 is compliant, soft feeling, andnon-irritating to the wearer's skin. A suitable inner layer 16 may bemanufactured from a wide range of materials, such as plastic films; orwoven or non-woven webs of natural fibers (e.g. wood or cotton fibers),synthetic fibers (e.g. polyester or polypropylene fibers), or acombination of natural and synthetic fibers, or composite materials suchas a film-coated nonwoven material. Preferably, for the embodiment shownin FIGS. 2 and 3, the inner layer of the chassis is a polymeric filmhaving a thickness of from about 0.012 mm (0.01 mil) to about 0.051 mm(2.0 mils).

In an alternate embodiment, the inner layer 16 may comprise anelastomeric laminate comprising an outer lamina, an inner lamina, end anelastomeric lamina joined between the inner and outer laminae. The innerand outer laminae are joined to the elastomeric lamina while theelastomeric lamina is in a laterally stretched condition such that thecontractive forces of the chassis are oriented in the cross machinedirection or perpendicular to the longitudinal centerline l of thechassis. Such a laminated chassis and methods of forming such alaminated chassis, are disclosed in commonly assigned, co-pending U.S.patent application No. 08/176,056 (P&G Case 5126), entitled "ElastomericDisposable Absorbent Article And Method of Making Same" which is beingfiled concurrently herewith in the name of Patrick J. Allen, et al., andwhich is incorporated herein by reference.

The outer layer 18 is that portion of the chassis 14 which will form theexterior of the chassis 14, i.e. face away from the wearer. The outerlayer 18 is compliant, soft feeling, and non-irritating to the wearer'sskin. A suitable outer layer 18 may be manufactured from a wide range ofmaterials, such as plastic films; or woven or non-woven webs of naturalfibers (e.g. wood or cotton fibers), synthetic fibers (e.g. polyester orpolypropylene fibers), a combination of natural and synthetic fibers, orcomposite materials such as a film-coated nonwoven material. The outerlayer 18 of the chassis 14 may also comprise a composite material havingtwo or more layers, wherein one or all of the layers are bloused fromthe inner layer 16. Thus, the outer layer 18 could comprise two or morelayers of a nonwoven material, or could comprise two or more filmlayers, or could comprise both nonwoven and film layers. Preferably, theouter layer 18 is a carded nonwoven web of polypropylene fibers. Asuitable outer layer is SPN 290 available from Fiberweb North America ofSimpsonville, S.C.

Preferably, the outer layer 18 will have a basis weight of about 20grams per square meter to about 40 grams per square meter. Morepreferably, the outer layer 18 will have a basis weight of about 25grams per square meter to about 35 grams per square meter. in apreferred embodiment, the outer layer will have a basis weight of about30 grams per square meter.

Blousing of the outer layer 18 may be accomplished by providing anoversized outer layer 18 and joining at least a portion of the peripheryof the oversized outer layer 18 along at least a portion of theperiphery of the inner layer 16. As used herein, the term "oversizedouter layer" will refer to an outer layer which is longer(longitudinally) and/or wider (laterally) than the inner layer 16. Ifthe absorbent article of the present invention is being produced on anautomated diaper converter which converts webs of material intoindividual diapers, the bloused outer layer 18 can be formed by feedingthe web of outer layer material into the converter at a rate greaterthan the rate at which the web of inner layer material is fed into theconverter, i.e., overfeeding the web of outer layer material.

The outer layer 18 will also have a decorative pattern or insignia 15printed on the surface thereof. Preferably, the pattern or insignia 15will be printed on the outer surface. The decorative insignia 15 willtend to draw the viewer's attention from the underlying inner layer 16and thereby will mask or hide the absorbent core 28 which is joined tothe inner layer 16 as discussed herein. The decorative insignia willpreferably be a repeating pattern. Examples of suitable decorativeinsignia would include a repeating pattern of ships, anchors, vehicles,bows, dinosaurs, teddy-bears, animals, flowers, or the like.

The outer layer 18 of the chassis 14 is positioned adjacent to the innerlayer 16 and is intermittently or partially joined thereto by attachmentmeans 40 such as those well known in the art. For example, the outerlayer 18 may be secured to the inner layer 16 by a uniform continuouslayer of adhesive, a patterned layer of adhesive, or an array ofseparate lines, spirals or spots of adhesive. Adhesives which have beenfound to be satisfactory are manufactured by Findley Adhesives of ElmGrove, Wis. and marketed as Findley 2031. Alternatively, the attachmentmeans may comprise heat bonds, pressure bonds, ultrasonic bonds, dynamicmechanical bonds, or any other suitable attachment means or combinationsof these attachment means as are known in the art. In a preferredembodiment of the present invention, the inner layer and the outer layerare directly joined along the mutually facing surfaces of theirperipheral areas 39. As used herein, the "periphery" or "peripheralarea" of an element, shall refer to the region, area, or zone adjacentthe boundary edges of that element.

The outer layer 18 will be intermittently or partially joined to theinner layer 16 such that at least portions of the common central areas17 of the inner layer 16 and the outer layer 18 are unadhered togetherand freely moveable relative to one another. As used herein, the term"central area" shall refer to the area of a material inboard of theperiphery, or peripheral area, of that material. The location of thepredetermined bonding areas 39 depends on the particular size and shapeof absorbent article. FIG. 3 shows attachment means, bond lines 40, thatintermittently join together the peripheral areas of the inner layer 16and the outer layer 18. Thus, the mutually facing surfaces of the innerlayer 16 and outer layer 18 that lie laterally inwardly of the bondlines 40 (i.e., central area 17), are substantially free to moverelative to each other.

It is not necessary that the peripheral area of the outer layer beentirely bonded to the peripheral area of the inner layer. It is onlynecessary that the outer layer be sufficiently bonded to the inner layersuch that the outer layer is held securely to the absorbent article. Itis also not necessary that the entire central area 17 of the outer layerbe detached from the inner layer, i.e., it is possible to have thebloused outer cover 18 intermittently joined to the inner layer 16 inthe central areas 17 provided portions of the central areas 17 aredetached and bloused. The intermittent bonding may be accomplished byspot bonding using ultrasonics, heat seals, or the like, orintermittently bonding using an adhesive pattern of dots or the like.

The bonded or joined surface area between the inner layer 16 and theouter layer 18 is preferably between about 10% to about 50% of themutually facing surface area between the inner layer 16 and the outerlayer 18. More preferably, the bonded or joined surface area between theinner layer 16 and the outer layer 18 is preferably between about 20% toabout 30% of the mutually facing surface area between the inner layer 16and the outer layer 18. In a particularly preferred embodiment; thebonded or joined surface area between the inner layer 16 and the outerlayer 18 is preferably about 25% of the mutually facing surface areabetween the inner layer 16 and the outer layer 18.

The combination of blousing the outer layer such that it hangs loosefrom the inner layer, and printing the outer layer such that a viewersattention is drawn away from the inner layer, results in the absorbentcore (or the outline of the absorbent core) being substantially maskedor hidden from the viewer and results in a more garment-like disposableabsorbent article.

The chassis 14 of the disposable training pants 20 preferably furthercomprises elasticized leg cuffs 32 for providing improved containment ofliquids and other body exudates. Each elasticized leg cuff 32 maycomprise several different embodiments for reducing the leakage of bodyexudates in the leg regions. (The leg cuff can be and is sometimes alsoreferred to as leg bands, side flaps, barrier cuffs, or elastic cuffs.)U.S. Pat. No. 3,860,003 entitled "Contractable Side Portions For aDisposable Diaper" issued to Buell on Jan. 14, 1975, describes adisposable diaper which provides a contractible leg opening having aside flap and one or more elastic members to provide an elasticized legcuff (gasketing cuff). U.S. Pat. No. 4,909,803 entitled "DisposableAbsorbent Article Having Elasticized Flaps" issued to Aziz and Blaney onMar. 20, 1990, describes a disposable diaper having "stand-up"elasticized flaps (barrier cuffs) to improve the containment of the legregions. U.S. Pat. No. 4,695,278 entitled "Absorbent Article Having DualCuffs" issued to Lawson on Sep. 22, 1987, describes a disposable diaperhaving dual cuffs including a gasketing cuff and a barrier cuff. U.S.Pat. No. 4,704,115 entitled "Disposable Waist Containment Garment"issued to Buell on Nov. 3, 1987, discloses a disposable diaper orincontinent garment having side-edge-leakage-guard gutters configured tocontain free liquids within the absorbent article. Each of these patentsare incorporated herein by reference. While each elasticized leg cuff 32may be configured so as to be similar to any of the leg bands, sideflaps, barrier cuffs, or elastic cuffs described above, it is preferredthat each elasticized leg cuff 32 comprise at least a side flap 104 withone or more elastic strands 105. Referring to FIG. 2, leg elastics 105are preferably positioned between the topsheet 24 and the inner layer 16of the chassis 14. Alternatively, the leg elastics 105 may be positionedbetween the inner layer 16 and the outer layer 18 of the chassis 14

The chassis 14 of the disposable training pants 20 further preferablycomprises an elasticized waistband 34 disposed adjacent the end edge 64of the disposable training pants 20 in at least the rear portion 58, andmore preferably has an elasticized waistband 34 disposed in both thefront portion 56 and the rear portion 58. The waistband of thedisposable training pants 20 is that portion which is intended to beplaced adjacent the wearer's waist. The elasticized waistband 34provides a member that maintains a defined area coverage, contacts thewearer's waist, and is elastically extensible in at least the lateraldirection so as to dynamically fit against the waist of the wearer andto dynamically conform to the waist of the wearer so as to provideimproved fit. Thus, the waistband is generally that portion of thedisposable training pants 20 extending from the end edge 64 of thedisposable training pants 20 to at least the waist edge 83 of theabsorbent core 28. While the elasticized waistband 34 can comprise aseparate element affixed to the chassis 14 of the disposable trainingpants 20, the waistband is preferably an extension of other elements ofthe disposable training pants 20 such as the topsheet 24, the innerlayer 16, or the outer layer 18, or any combination of these elementsand an elastomeric material joined thereto. Alternatively, the topsheet24 and the backsheet 26 of the absorbent assembly 22, may extend beyondthe edges of the absorbent core 28 and have an elastomeric materialjoined thereto to form an elasticized waistband. Disposabletraining-pants are often constructed so as to have two elasticizedwaistbands; one positioned in the front portion 56 and one positioned inthe rear portion 58. The disposable training pants 20 at least has anelasticized waistband 34 disposed in at least the central region 68 ofthe rear portion 58. Preferably, as shown in FIG. 2, another elasticizedwaistband is disposed in the front portion 56.

The elasticized waistband 34 may be constructed in a number of differentconfigurations. In a preferred embodiment of the present invention shownin FIG. 2, the elasticized waistband 34 comprises an elastic waistbandmember 76 interposed between the topsheet 24 and the inner layer 16 ofthe chassis 14 and operatively associated therewith to gather the frontportion 56 and rear portion 58 of the disposable training pants 20. Anexample of such an elasticized waistband for use herein is theelasticized waistband disclosed in U.S. Pat. No. 4,515,595 entitled"Disposable Diapers With Elastically Contractible Waistbands", whichissued to Kievit and Osterhage on May 7, 1985, and which patent isincorporated herein by reference.

Any suitable elastomeric material as known in the art may be used as theelastic waistband member 76 of the present invention. Examples ofsuitable elastomeric materials include elastomeric films, elastomericfoams such as polyurethane foams or crosslinked natural rubber foams;formed elastic scrim; elastomeric films such as heat shrinkable elasticmaterials; elastomeric film laminates such as a laminate of aheat-shrinkable elastomeric film and a resilient member; elastomericstretch laminates such as "zero strain" stretch laminates (as describedin U.S. Pat. No. 5,246,433 which issued to M. H. Hasse, S. W. Miller,and R. P. Bridges on Sep. 21, 1993, which is incorporated herein byreference) or mechanically stretched pretensioned stretch laminates; andelastic strands made from rubber, LYCRA, or other materials. In apreferred embodiment, the elastic waistband member 76 comprises a heatshrinkable elastomeric film.

ABSORBENT ASSEMBLY

The training pants 20 will also comprise an absorbent assembly 22comprising at least an absorbent core 28 joined to the inner layer 16.The absorbent assembly 22 of the disposable training pants 20, as shownin FIG. 3, may comprise a liquid pervious topsheet 24 joined to theinner layer 16 and an absorbent core 28 positioned between the topsheet24 and the inner layer 16. In an alternate embodiment of the presentinvention, shown in FIG. 4, the absorbent assembly 22 may be an insertcomprising a liquid pervious topsheet, a liquid impervious backsheetjoined to the topsheet, and an absorbent core positioned between thetopsheet and the backsheet.

The absorbent core 28 of the absorbent assembly 22, may be any absorbentmeans which is generally compressible, conformable, non-irritating tothe wearer's skin, and capable of absorbing and retaining liquids suchas urine and other certain body exudates. The absorbent core 28 may bemanufactured in a wide variety of sizes and shapes (e.g., rectangular,hourglass, "T"-shaped, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. Examples of other suitable absorbent materialsinclude creped cellulose wadding, meltblown polymers including coform,cross-linked cellulosic fibers, tissue including tissue wraps, absorbentfoams, absorbent sponges, superabsorbent polymers, absorbent gellingmaterials, or any equivalent material or combinations of materials. Theconfiguration and construction of the absorbent core may also be varied(e.g., the absorbent core may have varying caliper zones, a hydrophilicgradient, a superabsorbent gradient, or lower average density and loweraverage basis weight acquisition zones; or may comprise one or morelayers or structures). The total-absorbent capacity of the absorbentcore 28 should, however, be compatible with the design loading and theintended use of the disposable absorbent article 20. Further, the sizeand absorbent capacity of the absorbent core 28 may be varied toaccommodate wearers ranging from infants through adults.

A preferred embodiment of the absorbent assembly 22 has a modified hourglass-shape absorbent core 28 which is symmetric about the longitudinalcenterline l. While a preferred embodiment of the absorbent assembly 22has a modified hourglass-shaped absorbent core 28, it should beunderstood that the size, shape, configuration and total absorbentcapacity of the absorbent core 28 may be varied to accommodate wearersranging from infants to adults. Therefore, the dimensions, shape andconfiguration of the absorbent core may be varied (e.g., the absorbentcore may have a varying caliper, or a hydrophilic radiant, or may or maynot contain absorbent gelling materials). An exemplary absorbentstructure for use as the absorbent core 28 of the present invention thathas achieved wide acceptance and commercial success is described in U.S.Pat. No. 4,610,678 entitled "High-Density Absorbent Structures" issuedto Weisman and Goldman on Sep. 9, 1986. U.S. Pat. No. 4,673,402 entitled"Absorbent Articles With Dual-Layered Cores" issued to Weisman,Houghton, and Gellert on Jun. 16, 1987; and U.S. Pat. No. 4,888,231entitled "Absorbent Core Having A Dusting Layer" issued to Angstadt onDec. 19, 1989; also describe absorbent structures that are useful in thepresent invention. Each of these references are incorporated herein byreference.

The absorbent core 28 is preferably a batt of airfelt and particles ofabsorbent gelling material, about 13 centimeters wide (lateraldimension), about 37 centimeters long (longitudinal dimension) andapproximately 8 centimeters across the narrowest part of the crotchportion 57. Preferably, the portion of the absorbent core that will begenerally located in the front portion 56 and crotch portion 57 willhave a higher basis weight than the portion of the absorbent core thatwill be generally located in the rear portion 58. More preferably, theportion of the absorbent core that will be generally located in thefront portion 56 and crotch portion 57 will have a basis weight threetimes the basis weight of the portion of the absorbent core that will begenerally located in the rear portion 58. In a preferred embodiment ofthe absorbent core 28, about 25 centimeters of the absorbent core'slength will be generally located in the front portion 56 and crotchportion 57 and will have a basis weight of about 0.96 grams per squareinch, and 11 centimeters of the absorbent core's length will begenerally located in the rear portion 58 and will have a basis weight ofabout 0.28 grams per square inch.

Referring to FIG. 3, the absorbent assembly 22 preferably also comprisesa liquid pervious topsheet 24 which is joined to the inner layer 16 ofthe chassis such that the absorbent core 28 is positioned between thetopsheet 24 and the inner layer 16. The absorbent core 28 has a garmentsurface 100, a body surface 101, side edges 82 and end edges 83. Theinner layer 16 of the chassis 14 is positioned adjacent the garmentsurface 100 of the absorbent core 28 and is joined thereto by attachmentmeans (not shown) such as those well known in the art. For example, theinner layer 16 of the chassis 14 may be secured to the absorbent core 28by a uniform continuous layer of adhesive, a patterned layer ofadhesive, or an array of separate lines, spirals, or spots of adhesive.Adhesives which have been found to be satisfactory are manufactured byCentury Adhesives, Inc. of Columbus, Ohio and marketed as Century 5227;and by H. B. Fuller Company of St. Paul, Minn. and marketed as HL-1258.The attachment means will preferably comprise an open pattern network offilaments of adhesive as is disclosed in U.S. Pat. No. 4,573,986entitled "Disposable Waste-Containment Garment", which issued toMinetola and Tucker on Mar. 4, 1986, and which is incorporated herein byreference. An exemplary attachment means of an open pattern network offilaments comprises several lines of adhesive filaments swirled into aspiral pattern such as is illustrated by the apparatus and methods shownin U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S.Pat. No. 4,785,996 issued to Ziecker, et al. on Nov. 22, 1978; and U.S.Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. Each of thesepatents are incorporated herein by reference. Alternatively, theattachment means may comprise heat bonds, pressure bonds, ultrasonicbonds, dynamic mechanical bonds, or any other suitable attachment meansor combinations of these attachment means as are known in the art.

Preferably the inner layer 16 is impervious to liquids and ismanufactured from a thin plastic film, although other flexible liquidimpervious materials may also be used. As used herein, the term"flexible" refers to materials which are compliant and will readilyconform to the general shape and contours of the human body. The liquidimpervious inner layer 16 prevents the exudates absorbed and containedin the absorbent core 28 from wetting articles, such as bed sheets andgarments, which contact the disposable training pants 20.

The topsheet 24 of the absorbent article 20 is positioned adjacent thebody surface 101 of the absorbent core 28 and is preferably joinedthereto and to the inner layer 16 by attachment means (not shown) suchas those well known in the art. Suitable attachment means are describedherein with respect to joining the inner layer 16 to the absorbent core28. In a preferred embodiment of the present invention, the topsheet 24and the inner layer 16 are joined directly to each other in the areasextending beyond the absorbent core 28 and are indirectly joinedtogether by directly joining them to the absorbent core 28 by theattachment means (not shown).

The topsheet 24 is that portion of the chassis 14 which will form theinterior of the disposable training pants 20, and will contact at leastthe waist and legs of the wearer. The topsheet 24 of the absorbentarticle 20 is compliant, soft feeling, and non-irritating to thewearer's skin. Further, the topsheet 24 is liquid pervious permittingliquids (e.g., urine) to readily penetrate through its thickness. Asuitable topsheet may be manufactured from a wide range of materials,such as porous foams; reticulated foams; apertured plastic films; orwoven or nonwoven webs of natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester or polypropylene fibers), or acombination of natural and synthetic fibers. Preferably, the topsheet 24is made of hydrophilic material comprising about 20% to 30% rayon so asto feel wet and signal a discharge of urine to a toilet training child.

There are a number of manufacturing techniques which may be used tomanufacture the topsheet 24. For example, the topsheet 24 may be anonwoven web of fibers. When the topsheet comprises a nonwoven web, theweb may be spunbonded, carded, wet-laid, meltblown, hydroentangled,combinations of the above, or the like. A preferred topsheet is cardedand thermally bonded by means well known to those skilled in the fabricsart. A suitable topsheet is manufactured by Fiberweb North America ofSimpsonville, S.C. and is available as FPN 286.

In an alternate embodiment, shown in FIG. 4, the absorbent assembly 22may be an insert, i.e., an element formed separately from the chassisand inserted therein. The absorbent insert comprises a topsheet 24, aliquid impervious backsheet 26 joined to the inner layer 16, and anabsorbent core 28 positioned between the topsheet 24 and the backsheet26.

Referring to FIG. 4, the absorbent core 28 and the liquid pervioustopsheet 24 may be substantially the same as those described above. Thebacksheet will be impervious to liquids and will preferably bemanufactured from a thin plastic film, although other flexible liquidimpervious materials may also be used. The liquid impervious backsheet26 prevents the exudates absorbed and contained in the absorbent core 28from wetting articles, such as bed sheets and garments, which contactthe disposable training pants 20. The liquid impervious backsheet 26 maythus comprise a woven or nonwoven material, polymeric films such asthermoplastic films of polyethylene or polypropylene, or compositematerials such as a film-coated nonwoven material. Preferably, thebacksheet is a film having a thickness of from about 0.012 mm (0.5 mil)to about 0.051 mm (2.0 mils).

The size of the backsheet 26 is dictated by the size of the absorbentcore 28 and the exact disposable garment design selected. In a preferredembodiment, the backsheet 26 will wrap around at least the absorbentcore and possibly over the edge portions of the topsheet 24 in at leastthe crotch portion 57, so that the elasticized leg cuffs 32 will be freefrom any backsheet material, and, thus, are not inhibited by thebacksheet material. Alternatively, the topsheet 24 may wrap around thecore and under the edge portions of the backsheet 26 in at least thecrotch portion 57, or the topsheet 24 and the backsheet 26 may be"side-notched" in the crotch portion 57 so that the elasticized legcuffs 32 are not inhibited by the backsheet material.

The backsheet 26 will be joined to the inner layer 16 of the chassis 14by any means well known in the art. Suitable means of joining thebacksheet of the absorbent insert to the inner layer 16 are discussedherein with respect to joining the absorbent core 28 to the inner layer16.

SIDE SEAMS

The side seams 10 of the chassis 14 may be formed by any means wellknown in the art. For example, the seams may be sewn, adhesively bonded,ultrasonically bonded, heat sealed, or the like. Suitable methods offorming side seams on disposable absorbent articles, such as trainingpant, are discussed in U.S. Pat. No. 4,205,679 issued to Repke, et al.;U.S. Pat. No. 4,335,425 issued to Jones, et al.; U.S. Pat. No. 4,610,680issued to LaFleur, et al.; U.S. Pat. No. 4,619,649 issued to Roberts.;U.S. Pat. No. 4,747,846 issued to Boland, et al.; U.S. Pat. No.4,641,381 which issued to Heran, et al.; U.S. Pat. No. 4,610,681 issuedto Strohbeen, et al.; U.S. Pat. No. 4,909,804 issued to Douglas, Sr.;and U.S. Pat. No. 5,236,430 issued to Russell P. Bridges; which patentsare incorporated herein by reference.

In a preferred embodiment of the present invention, the side seams areformed by folding the chassis in the crotch portion 57 so that thelongitudinal side regions 88 of the front portion 56 are substantiallysuperposed with the longitudinal side regions 88 of the rear portion 58forming two seaming areas. As used herein, the term "superpose" willmean to place or set over or above something else such that all likeparts substantially coincide. The seam 10 is then formed by any of themeans well known in the art. Preferably, the seam is formed by applyingpressure and/or heat to the seaming area to effect a bond between thelongitudinal side regions of the front portion 56 and the longitudinalside regions 88 of the rear portion 58. Methods of using pressure and/orheat to form a bond between two or more elements, are described ingreater detail in U.S. Pat. No. 4,854,984, which issued to Ball et al.on Aug. 8, 1989 which is incorporated herein by reference.

Although the seams of the disposable article of the present inventionhave been shown and described herein as being fixed seams, i.e.,non-reusable seams, the disposable absorbent article of the presentinvention may be provided seams which allow the article to be opened andre-closed. Seams which allow disposable absorbent articles to be openedand re-closed are well known in the disposable diaper art. These typesof seams generally comprise tape tabs joined thereto to the frontportion or rear portion of the article. These tape tabs are providedwith an adhesive or mechanical fastening means capable of securing therear portion and front portion in an overlapping configuration about thelower torso of the wearer, and allow the article to be opened andre-closed. Such fastening systems are described in greater detail inU.S. Pat. No. 3,848,594 issued Nov. 19, 1974 to Buell; U.S. Pat. Nos.4,699,622 issued Oct. 13, 1987 to Toussant et al.; and U.S. Pat. Nos.4,846,815 issued Jul. 11, 1989 to Scripps; all of which are incorporatedherein by reference.

ALTERNATE EMBODIMENTS

An alternate embodiment of the present invention, is shown incross-section in FIG. 5. This embodiment comprises elasticized ear flaps30 that are unitary with the chassis 14. The elasticized ear flaps 30are formed by securing an elastomeric ear flap member 90 to each of theear flaps 72 of the chassis 14 to form an elastomeric laminate. Theelastomeric ear flap member 90 is joined to at least the inner layer 16of the chassis 14. Preferably, as shown in FIG. 5, the elastomericlaminate is formed by securing the elastomeric ear flap member 90between the inner layer and a portion of the topsheet 24 of theabsorbent assembly 22. Each of the ear flaps are then mechanicallystretched such that the ear flap is permanently elongated and thelaminate is elastically extensible in the direction of initialstretching, once the initial stretching forces are removed from thelaminate. Methods of forming unitary elasticized ear flaps are discussedin greater detail in U.S. Pat. No. 5,246,433, "Elasticized DisposableTraining Pant And Method Of Making The Same", which issued to M. H.Hasse, R. P. Bridges, and S. W. Miller on Sep. 21, 1993; and U.S. Pat.No. 5,236,430, "Disposable Training Pant Having Fusion Slit Side Seams",which issued to R. P. Bridges on Aug. 17, 1993; which patents are herebyincorporated herein by reference. Although the absorbent assembly 22 ofthe absorbent article of FIG. 5 comprises an absorbent core 28positioned between the topsheet 24 and the inner layer 16, the absorbentassembly 22 may comprises an "absorbent insert" such as is describedhereinbefore and shown in FIG. 4.

Other suitable training pant structures (without the bloused and printedouter layer of the present invention) are shown in U.S. Pat. Nos.4,205,679 to Repke, et al.; U.S. Pat. No. 4,610,680 to LaFleur; U.S.Pat. No. 4,610,681 to Strohbeen, et al.; U.S. Pat. No. 4,641,381 toHeran, et al.; U.S. Pat. No. 4,909,804 to Douglas, Sr.; and U.S. Pat.No. 4,960,414 to Meyer; all of which patents are incorporated herein byreference.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other charges and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A garment-like disposable absorbent article forwearing about a wearer's lower torso, comprising:a chassis having afront portion, a rear portion, a crotch portion, end edges, longitudinalside edges, a periphery adjacent to said end edges and said longitudinalside edges, and a central area inboard of said periphery, said chassiscomprising an inner layer comprising a liquid pervious material; anabsorbent assembly comprising a liquid impervious backsheet joined tosaid inner layer, a liquid pervious topsheet joined to said backsheet,and an absorbent core positioned between said topsheet and saidbacksheet; seams joining said longitudinal side edges of said frontportion to said longitudinal side edges of said rear portion so as toform two leg openings and a waist opening substantially encircled bysaid end edges; and an outer layer having a front portion, a rearportion, a crotch portion, end edges, longitudinal side edges, aperiphery adjacent to said end edges and said longitudinal side edges,and a central area inboard of said periphery, at least a portion of saidperiphery of said outer layer being joined to at least a portion of saidperiphery of said inner layer such that said central area of said outerlayer can blouse away from said central area of said inner layer atselected portions, said outer layer additionally having a patternprinted thereon, such that said inner layer with said absorbent assemblyjoined thereto is substantially unnoticeable to a viewer due to saidpattern and said bloused central area of said outer layer.
 2. Thedisposable absorbent article of claim 1 wherein said inner layer andsaid outer layer each comprise a liquid pervious nonwoven material.
 3. Agarment-like elasticized disposable absorbent article for wearing abouta wearer's lower torso, comprising:(a) a chassis having:(i) a frontportion having an end edge, longitudinal side edges, leg edges, acentral region, ear flaps, each said ear flap extending laterallyoutwardly from said central region to said longitudinal side region andlongitudinally along said central region from said end edge to said legedge; (ii) a rear portion opposed to said front portion, said rearportion having end edges, longitudinal side edges, leg edges, a centralregion, ear flaps, each said ear flap extending laterally outwardly fromsaid central region to said longitudinal side edges and longitudinallyalong said central region from said end edge to said leg edge; and (iii)a crotch portion between said front portion and said rear portion; saidchassis comprising: an inner layer having a front portion and a rearportion having ear flaps, each said ear flap extending laterallyoutwardly to said longitudinal side edges and longitudinally from saidend edge to said leg edge, a crotch portion, end edges, longitudinalside edges, a periphery adjacent to said end edges and said longitudinalside edges, and a central area inboard of said periphery; and an elasticear flap member joined to said inner layer at each said ear flap andextending longitudinally from said end edge of said ear flap toward saidleg edge of said ear flap to form an elastomeric laminate, each saidelastomeric laminate being mechanically stretched to form an elasticizedear flap in each said ear flap of said chassis, each said elasticizedear flap being unitary with said chassis in that said elasticized earflap comprise a portion of at least said inner layer; (b) an absorbentassembly comprising a liquid impervious backsheet joined to said innerlayer, a liquid pervious topsheet joined to said backsheet, and anabsorbent core positioned between said topsheet and said backsheet; (c)an outer layer having a front portion, a rear portion, a crotch portion,end edges, longitudinal side edges, a periphery adjacent to said endedges and said longitudinal side edges, and a central area inboard ofsaid periphery, at least a portion of said periphery of said outer layerbeing joined to at least a portion of said periphery of said inner layersuch that said central area of said outer layer can blouse away fromsaid central area of said inner layer at selected portions, said outerlayer additionally having a pattern printed thereon, such that saidinner layer with said absorbent assembly joined thereto is substantiallyunnoticeable to a viewer due to said pattern and said bloused centralarea of said outer layer; and (d) seams joining said front portion tosaid rear portion adjacent said longitudinal side edge so as to form twoleg openings and a waist opening substantially encircled by said endedges.
 4. The disposable absorbent article of claim 3 wherein said innerlayer comprises a liquid pervious material.
 5. The disposable absorbentarticle of claim 3 wherein said topsheet comprises about 20% to about30% rayon fibers.